Shipping and dispensing carton
A carton for holding a plurality of articles. The carton comprises a first side panel, a bottom panel, a second side panel, a first top panel, and a second top panel. The bottom panel comprises a first portion and a second portion. The carton comprises a first proximal side end flap, a first distal side end flap, a second proximal side end flap, a second distal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The first distal side end flap is in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
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This application is a continuation application of U.S. application Ser. No. 14/095,136, filed Dec. 3, 2013, which is a divisional of U.S. application Ser. No. 11/549,355, filed Oct. 13, 2006, which claims the benefit of U.S. Provisional Application No. 60/726,408, filed Oct. 13, 2005, and U.S. application Ser. No. 11/549,355 is a continuation-in-part of application Ser. No. 11/524,574, filed Sep. 21, 2006, which claims the benefit of U.S. Application Ser. No. 60/719,309, filed Sep. 21, 2005.
INCORPORATION BY REFERENCEU.S. patent application Ser. No. 14/095,136, which was filed on Dec. 3, 2013, U.S. application Ser. No. 11/549,355, which was filed on Oct. 13, 2006, U.S. Provisional Application No. 60/726,408, which was filed on Oct. 13, 2005, U.S. application Ser. No. 11/524,574, which was filed on Sep. 21, 2006, and U.S. Provisional Application No. 60/719,309, which was filed on Sep. 21, 2005, are hereby incorporated by reference for all purposes as if presented herein in their entirety.
BACKGROUNDCartons are typically shipped in bulk quantities. During shipping, the cartons may be vertically stacked upon each other in order to maximize the amount of product shipped in a particular vessel. The amount of product shipped may depend, however, on the load-bearing capacity of the stacked cartons. It is therefore desirable to produce cartons having high rigidity and/or strength in compression for shipping, and for other purposes such as the protection of the carton contents in general.
A conventional method for increasing the strength of a carton is to produce the carton from a blank of a different, stronger board material, or to produce the blank from the same carton material but of greater thickness. Such methods typically increase the costs associated with manufacturing the carton, with the material costs of manufacture generally increasing according to the cost of increasing the strength and/or thickness of the entire blank. Some sections of the blank, however, may not be load-bearing, and the additional costs associated with increasing the strength of non-load bearing sections of the blank are wasted.
SUMMARYIn general, one aspect of the disclosure is generally directed to a carton for holding a plurality of articles. The carton comprises a plurality of panels that extends around an interior of the carton. The plurality of panels comprises a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. A plurality of end flaps are respectively foldably connected to a respective panel of the plurality of panels and are at least partially overlapped to close an end of the carton. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The first distal side end flap is in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
In another aspect, the disclosure is generally directed to a blank for forming a carton.
The blank comprises a plurality of panels comprising a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. A plurality of end flaps are respectively foldably connected to a respective panel of the plurality of panels and are for being at least partially overlapped to close an end of the carton formed from the blank. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The first distal side end flap is positionable to be in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
In another aspect, the disclosure is generally directed to a method of forming a carton for containing a plurality of articles. The method comprises obtaining a blank comprising a plurality of panels comprising a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel. The bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line. The blank comprises a plurality of end flaps respectively foldably connected to a respective panel of the plurality of panels. The plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel. The method comprises positioning the plurality of panels to form an interior of the carton and positioning the plurality of end flaps to at least partially close an end of the carton. The positioning the plurality of end flaps comprises positioning the first distal side end flap to be in face-to-face contact with the second distal side end flap, positioning the first bottom end flap to be in face-to-face contact with the first proximal side end flap, and positioning the second bottom end flap to be in face-to-face contact with the second proximal side end flap.
The foregoing and other features, aspects, and advantages of the invention will become more apparent upon review of the detailed description of the preferred embodiments set forth below when taken in conjunction with the accompanying drawing figures, which are briefly described as follows.
According to common practice, the various features of the drawings discussed below are not necessarily drawn to scale. Dimensions of various features and elements in the drawings may be expanded or reduced to more clearly illustrate the embodiments of the invention.
Briefly described, the present invention is directed to cartons having enhanced strength and rigidity. The cartons are formed from primary blanks reinforced with one or more reinforcing blanks adhered to the primary blanks. In this specification, the terms “bottom,” “side,” and “top” are used to indicate orientations determined in relation to fully erected cartons placed in upright configurations, and are not intended to limit the scope of the invention.
Referring to
The first side panel 20 is foldably connected at each end to a first proximal side end flap 22, which is connected to a first distal side end flap 24. The bottom panel 30 is foldably connected at each end to two bottom end flaps 32. The bottom end flaps 32 are separated by transversely extending cuts 34. The second side panel 40 is foldably connected at each end to a second proximal side end flap 42, which is connected to a second distal side end flap 44. The first top panel 50 is foldably connected at each end to a first top end flap 52. The second top panel 60 is foldably connected at each end to a second top end flap 62. Handle apertures or knockouts 54 may be formed in one or both of the first and third top panels 50, 70. The end flaps 22, 24, 32, 42, 44, 52, 62 extend along a first and a second marginal area of the blank 6, and may be connected at first and second longitudinally extending fold lines 65, 66. The longitudinal fold lines 65, 66 may be straight, or they may be offset at one or more locations to account for, for example, blank thickness. The first side end flaps 22, 24 are foldably connected at longitudinal fold lines 25, and the second side end flaps 42, 44 are foldably connected at longitudinal fold lines 45.
The first reinforcing blank 8 has a perimeter that may be in part generally complementary to a part of the first marginal area of the primary blank 6. The first reinforcing blank 8 is meant to overlie a part of the first marginal area of the primary blank 6 in order to reinforce the blank 6. The first reinforcing blank 8 includes a strip 80 of sequentially arranged rectangular reinforcing panels 81, 82, 83, 84, 85, 86, 87, and foldably attached reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′. During erection, the blank 8 is placed over the primary blank 6 so that the reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′ of the first reinforcing blank 8 overlie and generally conform in shape to corresponding end flaps 62, 22, 32, 32, 42, 52, respectively, of the primary blank 6. The sequentially arranged reinforcing panels 81, 82, 83, 84, 85, 86, 87 are aligned with respective panels 60, 20, 30, 40, 50, 70 of the primary blank 6 so that the reinforcing blank 9 folds along the transverse fold lines 61, 31, 35, 41, 51, 71 in the primary blank 6.
Similarly, the second reinforcing blank 9 has a shape that may be in part generally complementary to a part of the second marginal area of the primary blank 6, and is meant to overlie and reinforce a second part of the first blank 6. The second reinforcing blank 9 includes a strip 90 of sequentially arranged rectangular reinforcing panels 91, 92, 93, 94, 95, 96, 97, and reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′. During erection, the second reinforcing blank 9 is placed over the primary blank 6 so that the reinforcing end flaps 62′, 22′, 32′, 32′, 42′, 52′ of the reinforcing blank 9 overlie and generally conform in shape to the end flaps 62, 22, 32, 32, 42, 52 of the primary blank 6. The reinforcing panels 91, 92, 93, 94, 95, 96, 97 are aligned with respective panels 60, 20, 30, 40, 50, 70 of the primary blank 6 so that the second reinforcing blank 9 folds along the transverse fold lines 61, 31, 35, 41, 51, 71 of the primary blank 6. Portions of the second reinforcing blank 9 may be, for example, a mirror image of the first reinforcing blank 8, and certain common reference numerals are therefore used in the reinforcing blanks 8 and 9.
The third reinforcing blank 407 is designed to overlie and reinforce a central section of primary blank 406. The third reinforcing blank 407 comprises a series of sequentially arranged reinforcing panels 471, 472, 473, 474, 475, 476, 477. During erection, the third reinforcing blank 407 is placed over the primary blank 406 so that the reinforcing panels 471, 472, 473, 474, 475, 476, 477 overlie and are adhered to the panels 460, 420, 430, 440, 450, 470 of the primary blank 460. The resultant multi-ply blank 410 formed from the blanks 406, 407, 408, 409 is shown in
Referring to
Referring to
According to the above embodiments, a primary blank can be reinforced at selected locations by reinforcing blanks. The carton formed from the resulting multi-ply blank can accordingly have enhanced strength and rigidity at selected sections of the carton. According to the present invention, selected reinforcement of specific areas of the primary blank can produce a high strength carton while using relatively small amounts of board.
One or more of the reinforcing blanks discussed above may be omitted in the above embodiments, for example, if a lesser amount of reinforcement is sufficient for a particular application.
In accordance with the exemplary embodiments, the cartons may be constructed of paperboard, for example. The blanks, and thus the cartons, can also be constructed of other materials, such as cardboard, solid unbleached sulfate (SUS) board, or any other material having properties suitable for enabling the carton to function at least generally as described above.
In one exemplary embodiment, the primary and reinforcing blanks are formed from SUS board. The primary blank has a caliper in the range of about 14-30 point, which may be more specifically in the range of about 18-26 point. The caliper of the reinforcing blanks can be slightly less than the primary blank, and can be in the range of about 14-20 point.
The blanks can also be laminated to or coated with one or more additional sheet-like materials at selected panels or panel sections. One or more panels of the blanks discussed above can be coated with varnish, clay, or other materials, either alone or in combination. The coating may then be printed over with product, advertising, and other information or images. The blanks may also be coated to protect any information printed on the blanks. The blanks may be coated with, for example, a moisture barrier layer, on either or both sides of the blanks.
In accordance with the above-described embodiments of the present invention, a fold line can be any substantially linear, although not necessarily straight, line of disruption or other form of weakening that facilitates folding therealong.
In the present specification, a “panel” or “flap” need not be flat or otherwise planar. A “panel” or “flap” can, for example, comprise a plurality of interconnected generally flat or planar sections.
The above embodiments may be described as having one or more panels adhered together by glue. The term “glue” is intended to encompass all manner of adhesives commonly used to secure carton panels in place.
The foregoing description of the invention illustrates and describes the present invention. Additionally, the disclosure shows and describes only selected embodiments of the invention, but it is to be understood that the invention is capable of use in various other combinations, modifications, and environments and is capable of changes or modifications within the scope of the inventive concept as expressed herein, commensurate with the above teachings, and/or within the skill or knowledge of the relevant art.
Claims
1. A carton for holding a plurality of articles, the carton comprising:
- a plurality of panels that extends around an interior of the carton, the plurality of panels comprises a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel, the bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line; and
- a plurality of end flaps respectively foldably connected to a respective panel of the plurality of panels and being at least partially overlapped to close an end of the carton, the plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel,
- the first distal side end flap is in face-to-face contact with the second distal side end flap, the first bottom end flap is in face-to-face contact with the first proximal side end flap, and the second bottom end flap is in face-to-face contact with the second proximal side end flap.
2. The carton of claim 1, wherein the plurality of end flaps comprises a first top end flap foldably connected to the first top panel and a second top end flap foldably connected to the second top panel.
3. The carton of claim 2, wherein the first distal side end flap is adhesively attached to the second distal side end flap.
4. The carton of claim 2, wherein the first bottom end flap and the second bottom end flap are separated by a cut.
5. The carton of claim 2, wherein the first top end flap is in face-to-face contact with the second proximal side end flap and the second top end flap is in face-to-face contact with the first proximal side end flap.
6. The carton of claim 5, wherein the plurality of panels comprises a third top panel foldably connected to the first top panel.
7. The carton of claim 6, wherein the third top panel is in face-to-face contact with the second top panel.
8. The carton of claim 7, wherein the second top panel is adhesively attached to the third top panel.
9. A method of forming a carton for containing a plurality of articles, the method comprising:
- obtaining a blank comprising a plurality of panels comprising a first side panel, a bottom panel foldably connected to the first side panel, a second side panel foldably connected to the bottom panel, a first top panel foldably connected to the first side panel, and a second top panel foldably connected to the second side panel, the bottom panel comprises a fold line that divides the bottom panel into a first portion and a second portion foldably connected to the first portion at the fold line, the blank comprises a plurality of end flaps respectively foldably connected to a respective panel of the plurality of panels, the plurality of end flaps comprises a first proximal side end flap foldably connected to the first side panel, a first distal side end flap foldably connected to the first proximal side end flap, a second proximal side end flap foldably connected to the second side panel, a second distal side end flap foldably connected to the second proximal side end flap, a first bottom end flap foldably connected to the first portion of the bottom panel, and second bottom end flap foldably connected to the second portion of the bottom panel;
- positioning the plurality of panels to form an interior of the carton;
- positioning the plurality of end flaps to at least partially close an end of the carton, the positioning the plurality of end flaps comprises positioning the first distal side end flap to be in face-to-face contact with the second distal side end flap, positioning the first bottom end flap to be in face-to-face contact with the first proximal side end flap, and positioning the second bottom end flap to be in face-to-face contact with the second proximal side end flap.
10. The method of claim 9, wherein the plurality of end flaps comprises a first top end flap foldably connected to the first top panel and a second top end flap foldably connected to the second top panel.
11. The method of claim 10, wherein the positioning the plurality of end flaps comprises positioning the first top end flap to be in face-to-face contact with the second proximal side end flap and positioning the second top end flap to be in face-to-face contact with the first proximal side end flap.
12. The method of claim 11, wherein the plurality of panels comprises a third top panel foldably connected to the first top panel and the positioning the plurality of panels comprises positioning the third top panel to be in face-to-face contact with the second top panel.
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Type: Grant
Filed: Jan 7, 2016
Date of Patent: Jan 17, 2017
Patent Publication Number: 20160114930
Assignee: Graphic Packaging International, Inc. (Atlanta, GA)
Inventors: Andrea Coltri-Johnson (Sao Paulo), Jean-Manuel Gomes (Acworth, GA), Edward W. Jones (Hiram, GA)
Primary Examiner: Gary Elkins
Application Number: 14/990,373
International Classification: B65D 5/18 (20060101); B65D 5/54 (20060101); B65D 5/66 (20060101); B65D 5/00 (20060101); B65D 5/44 (20060101); B65D 5/52 (20060101); B65D 71/36 (20060101); B31B 1/25 (20060101); B31B 1/26 (20060101); B31B 1/90 (20060101); B31B 7/00 (20060101); B65D 5/56 (20060101); B65D 5/70 (20060101); B65D 5/72 (20060101); B65D 5/02 (20060101); B65D 5/42 (20060101);